Modular, transportable, insulated building, with water, and fire resistant floor, wall, and roof panel, pre-manufactured assemblies

ABSTRACT

A small, heavy duty, transportable building having pre-manufactured panel assemblies made out of magnesium oxide for the floor, wall and roof that are quickly fastened together, on site, using common metal screws. All building materials are inorganic for extreme mold and mildew resistance. Furthermore, the building panels are configured and fastened together for inherent insulative fire and flood resistant properties. Commercial metal strut forms an economic protective perimeter around the magnesium oxide surface panels, and offer a fastening means to adjoining panels. The uses of the building (bunker, enclosure, shelter, shed, little-house, etc. . . . ) are myriad and not intended to be limited in usefulness. In addition, the building configurations and square footage options are limitless, single wide building ways, storied if desired. The design also allows manufacturing of the panel assemblies with common, hand tools, power tools, and welding equipment. No crane is needed for building erection.

REFERENCES CITED

U.S. Patent Documents 5,678,384 October 1997 MAZE 6,460,297 October 2002BONDS et al. 8,925,255 B1 January 2015 HAUN et al. 9,115,504 B2 August2015 WALLACE 9,121,168 B2 September 2015 LEVY et al. 9,212,485 B2December 2015 WOLYNSKI et al.

BACKGROUND

A need exists for small economic, rugged, insulated, transportable, fireand water resistant, buildings, for security of persons and/or property.

A further need exists for flexible building configurations designed inmodular lengths to allow for custom solutions to meet additional ownerrequirements.

An additional need exists that these buildings may be quickly erectedmanually, on site, without the need of mixed and cured concrete usingcommon hand tools.

The present flexible embodiments meet these needs.

BRIEF SUMMARY OF INVENTION

The present embodiments generally relate to floor, wall, roof, andpre-manufactured building structures resistant to abnormal or extremeexternal or internal conditions. The structures of the present inventionare useful in applications where a transportable, building requires ahigh degree of fire, mold, termite, and water resistant performance.

Furthermore, the building design is economic, simple, rugged, andprovides security. It can be assembled with 2 persons, without a craneon site and no mixed concrete is required for installation.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description will be better understood in conjunction withthe accompanying drawings as follows:

FIG. 1 depicts a building (partially shown for structural clarity)formed according to one embodiment. Other embodiments have a similargable end width, but different lengths and door and window penetrationsdetermined by end user.

FIG. 2 depicts a sidewall assembly (without window perforation)according to one or more embodiments. End wall assembly panels aresimilar, and in one embodiment, the design has a slope and plateau upperedge section(s). Sliding doors are made in a similar manner.

FIG. 2A depicts a vertical side section of a sidewall or door assemblyaccording to one or more embodiments showing the metal strut crosssection, weld captivating feature, at least one or more commerciallyavailable layered glass reinforced MGO boards. Also shown are the airgaps and metal screen thermal break surface.

The present embodiments are detailed below with reference to the listedFigures.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Before explaining the present design in detail, it is to be understoodthat the enclosure is not limited to the particular embodiments and thatit can be practiced or carried out in various ways.

In an embodiment of the invention, pre-fabricated multi-layered, MGOwall panel assemblies' (or structures) are joined side to side on top oflevel adjusted subfloor panel assemblies, finished floor concrete, orconcrete walls (block or poured). Fasteners can join the adjoining metalperimeter edges together. Multiple wall panels can be straight or atvarious angles, that can be joined to form the outer walls of abuilding.

The building can include single story and second story wall structures.For single story building embodiments, the design and construction isseismic and wind resistant to a maximum wind gust of 156 MPH (CATAGORY 4HURRICANE 130-156 MPH).

In another embodiment of the invention that forms the basic protectiveshell, all electrical conduit, supply plumbing, and other humanconveniences may be installed on the inside surface of the wall(s) andor roof truss(es).

A building exhaust vent or vents may be installed in the center roofsupport structure and can exhaust out the ends of the gables. The designallows for 3″ type B, double walled, gas vent that has a maximum OD ofup to 4″. The inner area of the roof support channel(s) may be used as acombination space for electrical cables, wires, water and gas piping,air ducting for HVAC purposes and insulation.

A door or double doors can be inserted in place of one or two of thewall panels respectively, creating an easy ingress or egress to thebuilding where needed.

The building has an all-metal skeletal frame construction in combinationwith high heat resistant layered glass reinforced MGO boards for fireresistance in the case of an adjacent burning building or other burningfuel source.

The building, in all embodiments, will survive at least 3 feet of wetsnow on the roof, providing a strong building for shelter against theheaviest snow and ice accumulations.

Single level building embodiments, will survive a category 4 hurricanewhen secured to 36″ deep set stakes at all designed locations orsecurely fastened to a concrete foundation.

An assembled 8′×12′ building (or smaller) can be quickly airlifted, viaa 3″ pipe (or 4″ tube) through the gable vent holes, to a site of anatural disaster and set in place and serve as a triage location forvictims of a mudslide, tornado or earthquake stricken area.

The 8′×12′ building (or smaller) is economical to move, with easy widespan (>4′-6″)×9′ long forklift access for lifting of the entire buildingwithout disassembly if desired.

In various embodiments, the building may be assembled, before deliveryto the end user with various optional electrical and plumbingenhancements, thus allowing the building to be in a more advancedfinished state, verses an onsite-erected building from a palleted kit.

The bare 8′×8′ building weighs approximately 2,100 lbs, and can bequickly deployed as an emergency shelter(s) after a natural disaster,using helicopter air lift or pickup truck transport directly to thesite(s) of greatest need.

Various embodiments may be optionally outfitted with basic utilities andfixtures to meet international codes for safe human habitation. Anegress-sized window (or smaller) may be installed in any vertical wallin the building. An outer building perimeter, semi vented, skirtrequired by many local codes protects the sub floor area water linesfrom freezing damage.

Simple expansion in predesigned configurations of initial floor spaceconfiguration is allowable based on future need. Alternately,contraction of floor space future requirements is similarly possible.

The Following Definitions are Used Herein.

The term “door” as used herein can refer to a conventional sliding orpivoting door to the building.

The term “fasteners” as used herein can refer to rivets, bolts, staples,as well as screws.

The term “filleted” as used herein can refer to corners that are cut toa rounded or chamfered edge.

Turning Now to the Figures for Detail Explanation;

FIG. 1 depicts a building 1300 with some roof panels 108 and side panels123 removed for structural clearness, formed according to oneembodiment. Other embodiments can have a similar gable end width definedby end panels 125, but different lengths.

At a minimum, one door 104 and window penetration is installed in door.

The present shown building 1300, embodied is a dash 06 configuration,nominally measuring 24′ in length, representing the width of six 4′ widefloor panels 120 and side panels 123 along the length. The allowablestraight length is not limitless. It can meet performance specificationsif a longer length is wanted only if the building is shaped like an “L”with the short leg being two panels wide. Then the structure may becontinued for up to an additional six panels in length. Continue thispattern, building to either side, up to a maximum of six panels inlength allowing foot print configurations that are unlimited. Buildingto the side is necessary to support lateral high wind loads or seismicloads.

The embodiment shows some of the required levelers 145 at the ends oflinear floor support 121 to allow the floor to be adjusted plum flat toan uneven ground placed, Concrete Masonry Unit 112 (CMU 112) supportingsurface. Anchor stakes 103 can be driven into undisturbed or compactedsoil at all building corners at a minimum. Holdown means may beaccomplished with chain and turnbuckles 102. For maximum wind andseismic load resistance, install anchor stakes 103 and filleted holdownsat all leveler 145 support points. An outer building perimeter, semivented, skirt 111 protects the sub floor area water lines from freezingdamage. The PVC skirt 111 also blocks animals from intrusion into thesubfloor area and provides some insulation.

The building can be stacked one level up (not shown). This allows anupper second story configuration to support the concept of modularbuilding design.

Multiple drill point screws 155 can be drilled into the end panels 125through clearance holes on the side panels 123. Embodied additionalscrews fasten the end floor panel 120 to end panels 125 through a Tbracket 138. Steel holdown straps can be welded to floor beam support121 and can be screwed into floor panels 120, side panels 123 and cornercolumn strut 132 where a door exists.

Multiple drill point screws 157 can then drill down through the metalroofing and MGO structural insulated panel assembly into steelsupporting structure underneath, such as the vented C roof support 127and the truss assembly 119.

Shown in the current embodiment is a door panel 104 that opens to theside on embodied overhead ball bearing rollers. A door header 137 can beutilized to complete the structural opening.

Structurally connecting the side panels at the top can be a roof drillplate 130 into which the roof screws 157 can be drilled into and affixedto.

The embodied building design can be airlifted, as an entire assembledstructure, with some interior payload, up to an 8′>12′ (or dash −03configuration). The process can begin by removing the vent covers orexhaust plumbing from the side pick plates 129 and thread a 14′ schedule40, aluminum, 3½″ pipe, through the 2 holes. Then the pipe can besecured from sliding longitudinally, with a couple of hose clamps. Thena helicopter may lift the building to a remote location. Re-level thefloor and use the building.

In embodiments, a quick release pin with a combination or keyed lock canbe used for securing the door from the outside. The quick release pincan be used to secure the door from the inside.

In embodiments, extra thermal insulation may be added to the undersideof the vaulted ceilings. The thickness of the extra insulation materialcan be up to 1½″ thick and still allow plenum room for a 36″ fan (notshown) surface mounted under the central C roof support 127.

The inner area 113 of the central C roof support channel(s) may be usedas a combination space for vents, electrical cables, wires, water andgas piping, air ducting for HVAC purposes and insulation.

All panel to panel abutting joints interior and exterior can be siliconcaulked for weather sealing. Sliding doors are sealed with nylon brushseals on top and sides. Bottom seal is a commercially availablethreshold type seal.

FIG. 2 depicts a sidewall panel 123 assembly (without windowperforation) according to one or more embodiments. End wall assemblypanels 125 can be similar, and in one embodiment design, the end wallpanel has a slope and plateau upper edge section(s).

In this embodiment, strut edge 209 and dual strut edges 210 are miterjoint welded together on 3 sides. Then the inner layered glassreinforced MGO board 203 can be slide inserted from the open end withthe thermal break screen 214. Due to the fire resistant nature of theMGO board, then a top strut edge 209 can be welded in place, capturingMGO board 203. This process is critical in creating an extremely fireresistant panel assembly. MGO cross studs 205 and MGO backer strips 207can then be added with a paste like adhesive 215 to wedge MGO board 203in place. At this construction point, additional adhesive 215 is spreadon outer surfaces of MGO cross studs 205 and MGO backer strips 207 andthe outer MGO board 204 is set in place, drilled and mechanicallyfastened together. Grind all miter joint welds flush.

In one embodiment, stainless steel (SS) screws 218 can be inserted inthe drilled holes from the outside, and tightened in place with a SSflanged nut 220.

Four drilled vent holes in the strut edge corners allow sealing innerand outer perimeter joints between MGO board and steel strut withadhesive 215. Applying primer paint to all sides can finish the panelassembly 123. Final paint coats can be applied after field assembly ofthe building.

This described process can provide rugged edge protection of MGO boardsfrom flaking and breakage, and provide strong fastening surfaces toadjacent panels and roof structures.

Similar fabrication techniques are employed for the door and floor panelassemblies.

Panel assemblies made in this manner are inherently resistant to shearforces or compressive forces parallel to the surface plains of thepanels.

FIG. 2A depicts a vertical side section detail of a sidewall panelassembly 123 according to one or more embodiments.

In this embodied detail, common, commercially available steel (orstainless steel) strut edge 209 and dual vertical strut edges 210 of thesame material, are miter joint welded together on 3 sides. Then theinner glass reinforced MGO board 203 can be slide inserted from the openend with the thermal break screen 214. Then due to the fire resistantnature of the MGO board, a top strut edge 209 (not shown) can be weldedin place capturing the inner MGO board 203 and thermal break screen 214.MGO board 203 cannot then be removed from within the strut edges at thispoint unless one breaks the board. MGO cross studs 205 and MGO backerstrips can then be added on top of screen 214 with a paste like adhesive215 to wedge MGO board 203 in place. Additional adhesive 215 can bespread on outer surfaces of MGO cross studs 205 and MGO backer strips207 and the outer MGO board 204 is set in place, match drilled andfastened together.

In one embodiment, stainless steel (SS) screws 218 can be inserted inthe drilled holes from the outside, and tightened in place with a SSflanged nut 220.

This described process can provide inherent highly thermally insulatedpanels due to the inefficiencies of passing conducted heat throughscreen. Inserted screen 214 decreases heat transfer and can providefuture spacing for sheets of Kevlar and/or steel (bullet resistantpanel), Polyurethane (blast resistant panel), very fine wire cloth(electromagnetic resistant panel if properly grounded), and/or lead(radiation resistant panel). Other attractive properties can be achievedor enhanced with other inserted material embodiments.

The air pockets shown can be partially filled with other insulativematerials as desired, like Reflectix™ radiant barrier laminate roll.

While these embodiments have been described with emphasis on theembodiments, it should be understood that within the scope of theappended claims, the embodiments might be practiced other than asspecifically described herein.

What is claimed is:
 1. A modular designed, screw together,semi-permanent, pre-manufactured transportable building (or bunker,enclosure, shed, shelter, little-house, tiny-house, etc. . . . ),designed, exclusively using non-combustible building materials, madeprimarily (by weight) of glass reinforced Magnesium Oxide (MGO) board,used in its construction, incorporating steel framed, wall, door andfloor panel assemblies, thus allowing simple onsite assembly,disassembly, and transport of said building.
 2. An improved modularbuilding as in claim 1 wherein the pre-manufactured panel assemblies allweigh less than 200 lbs allowing site erection without the use of acrane.
 3. An improved modular building as in claim 1 wherein thefoundation can be concrete masonry blocks directly laid on undisturbed,organically cleaned, bare soil at different heights within a range of2½″.
 4. An improved modular building as in claim 1 wherein the subfloormay be adjusted to a horizontal plane by the use of common swivel footlevelers.
 5. An improved modular building as in claim 1 wherein a 2ndstory may be added to the building layout.
 6. An improved modularbuilding as in claim 1 wherein simple expansion is allowable inpredesigned configurations, of the initial floor space configuration,based on future need.
 7. An improved modular building as in claim 1wherein the bare interior surfaces and materials are as fire, water andmold resistant as the exterior surfaces.
 8. An improved modular buildingas in claim 1 wherein the fully assembled building, (less than 100 SF insize), may be air lifted via helicopter suspended from the vent holes atthe top center of the end gables.
 9. An improved modular building as inclaim 1 wherein the panel assemblies have a minimum 1½ hr fireresistance rating as per ASTM E119.
 10. An improved modular building asin claim 1 wherein the shipping design for the floor and wall panelassemblies may be pancake stacked, up to 25 high, without damage. 11.Floor and wall panel assemblies of multi layered, glass reinforcedMagnesium Oxide (MGO) boards, glued and mechanically fastened together(with screws, bolts, rivets, staples . . . etc), and at least one MGOpanel is weld captured in a metal frame.
 12. An improved panelassemblage as mentioned in claim 11 wherein the metal edge frame wrapsaround at least one MGO board and is for the edge protection of saidboards
 13. An improved panel assemblage as mentioned in claim 11 whereinthe plain metal edge is match drilled and screwed together via bracketsto adjacent panel assemblies using common drill point screws.
 14. Animproved panel assemblage as mentioned in claim 11 wherein at least ¼ ofthe resisting structural strength against normal vectored physical loads(wind, seismic, riot, flood, etc. . . . ) is derived by separating twoMGO sheathing boards by short span, cross slats, of the same thicknessMGO sheathing material, sandwiched, glued and fastened together.
 15. Animproved panel assemblage as mentioned in claim 11 wherein the panelshave no bio-originated materials in their assembly, yielding a moldresistant, termite resistant, and water resistant panel.
 16. Using anassemblage of glass reinforced Magnesium Oxide (MGO) boards that aredesigned by their separation, in combination with at least one sandwichlayered coarse metal screen acting as a thermal conductive brake, andincluding at least 2 boards, separated by multiple horizontal airpockets for the default design configuration to produce a highlythermally insulating panel for the given thickness.
 17. An improvedthermal panel assemblage as mentioned in claim 16 wherein common,commercially available, metal “strut” is used for the panel perimeteredge protection and is a component of the overall exoskeletal structureof a building.
 18. An improved thermal panel assemblage as mentioned inclaim 16 wherein at least one sandwich layered coarse metal screenthickness may be substituted with insertion of other materials toenhance other (than thermal) desired properties like additionalstructural stiffness, bullet resistance, blast resistance,electromagnetic resistance, radiation resistance etc.